Landscaping products including continuous chamber mass confinement cells and methods of use therof

ABSTRACT

The present invention relates to environment resistant landscaping products, such as retaining wall and earth retention products, edgers, paving stones and the like, that provide a natural earthen appearance, such as rock, stone, sand, soil, clay, wood, trees and foliage, water, or any other natural earthen appearance. The present invention also includes a mass confinement cell that may be used in retaining walls and earth retention systems that has a natural earthen appearance and is resistant to damage and wear caused by the environment. The mass confinement cells are generally light-weight and include a continuous chamber that at least partially aligns with confinement cells positioned above and below, thereby allowing the intermingling of fill material between adjacent cells. The mass confinement cells are capable of accepting and retaining any type of filling material. The filling material provides weight, stability and security to a retaining wall constructed of such mass confinement cells.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.11/463,820 filed on Aug. 8, 2006, which is a continuation in partapplication of U.S. application Ser. No. 11/126,546 filed on May 11,2005, which claims priority to U.S. Provisional Application Ser. No.60/569,886 filed on May 11, 2004; U.S. application Ser. No. 11/463,820further claims priority to U.S. Provisional Application Ser. No.60/707,032, filed on Aug. 10, 2005, U.S. Provisional Application No.60/741,737 filed on Dec. 2, 2005, U.S. Provisional Application No.60/777,617 filed on Feb. 28, 2006, and is related to U.S. applicationSer. No. 11/463,816 filed on Aug. 10, 2006. The contents of the sevenpreviously mentioned applications are incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to environment resistant landscapingproducts, such as retaining wall and earth retention products, edgers,paving stones and the like, that provide a natural earthen appearance,such as rock, stone, sand, soil, clay, wood, trees and foliage andwater, or any desired design and/or appearance. The present inventionalso includes a mass confinement cell that may be used in retainingwalls and earth retention systems that has a natural earthen appearanceor other aesthetic design and is resistant to damage and wear caused bythe environment. The mass confinement cells are generally light-weightand include a continuous chamber that at least partially aligns withconfinement cells positioned above and below, thereby allowing theintermingling of fill material between adjacent cells. The massconfinement cells are capable of accepting and retaining any type offilling material that generally provides weight, stability and securityto a retaining wall constructed of such mass confinement cells.

BACKGROUND OF THE INVENTION

The use of retaining walls to protect and beatify property in all typesof environmental settings is a common practice in the landscaping,construction and environmental protection fields. Walls constructed fromvarious materials are used to outline sections of property forparticular uses, such as gardens or flower beds, fencing in propertylines, reduction of erosion, stabilizing construction sites inpotentially unstable and/or rough terrain and to simply beautify areasof a property.

Numerous methods and materials exist for the construction of retainingwalls. Such methods include the use of natural stone, poured in placeconcrete, masonry, landscape timbers or railroad ties. In recent years,segmental concrete retaining wall units, sometimes known as dry-castblock, which are dry stacked (i.e., built without the use of mortar),have become a widely accepted product for the construction of retainingwalls. Examples of such units are described in U.S. Pat. No. RE 34,314(Forsberg) and in U.S. Pat. No. 5,294,216 (Sievert).

However, many of the materials utilized in the construction of retainingwalls are susceptible to deterioration, heavy, cumbersome and/or notvery aesthetically appealing. The ability of these retaining walls towithstand sunlight, wind, water, general erosion and other environmentalelements is a problem with most retaining wall products.

One particular concern is the utilization of erosion protectionmaterials in water shorelines. Leaving the shoreline natural can lead toerosion, cause an unmanageable and unusable shoreline, create highmaintenance, and potentially destroy an aesthetically pleasing property.Many materials utilized in retention of shorelines are subject toimmediate deterioration and/or are not as aesthetically appealing as onewould desire. Furthermore, many materials utilized on shorelinestructures are difficult to maintain due to the awkward location in thewater and also the prevalent growth and presence of organic materialsthat can get caught and flourish in such a structure. For example, manylakeshore or ocean side properties utilize riprap as a retention devicefor prevention of erosion. Riprap is a configuration of very heavy,large to medium size stones placed along the shoreline. One problem withwaterfront properties that use a continuous wall of typical riprap isthe shoreline will retain some organic material, will accumulateadditional organic material brought in by the water and/or will allowvegetation to grow within the openings between stones. This usuallyleads to an unmanageable and aesthetically displeasing shoreline orhigher maintenance. Furthermore, the riprap is never uniform in colorand size and therefore does not provide the most aesthetically pleasingshoreline or complete coverage of the shoreline. The lack of uniformshoreline coverage allows for some erosion, collection of unwantedmaterials and the potential growth of undesirable vegetation.

Another problem with materials normally utilized in the construction ofretaining walls, such as poured in place concrete, masonry, landscapetimbers, railroad ties or dry-cast blocks (e.g. blocks produced byKeystone® Inc. or Anchor® Retaining Wall Systems, Inc.) is thatregulations in most states and counties prohibit their use in or nearbodies of water because of the potential chemical diffusion into thebody of water and/or the crumbling or deterioration of the material intothe body of water over time. Many of these retaining wall materialsdiffuse chemicals, dissolve, crumble, break apart and/or float into thebody of water of which they are lining, thereby causing problems withthe shoreline and pollution of the water. For example, the average lifeof various types of dry-cast block in water environments isapproximately a couple of years. A need exists for a retaining wall,which would be resistant to such deterioration.

An additional concern that exists in the construction of retaining wallsis the weight of the materials. Concrete blocks (e.g. wet or dry cast),large or medium size stones or timbers can be heavy and cumbersome tomove into the wall location and maneuver when constructing retainingwalls and earth retention systems. Many locations for which retainingwalls are constructed are positioned in awkward terrain. Therefore,heavy building materials are difficult to move into such locations andfurthermore are difficult to position when constructing the retainingwall, thereby adding additional cost and labor for installation.However, the heavy materials can be beneficial once the wall isconstructed to provide stability and security to the structure.Therefore, what is needed are easy to install light-weight units usedfor the construction of retaining walls and earth retention systems,which can be weighted once placed into position thus retaining the unitsin position and stabilizing the completed retaining wall.

SUMMARY OF THE INVENTION

Embodiments of the present invention relate to retaining wall productsincluding mass confinement cells that are resistant to damage and wearcaused by the environment. The mass confinement cells generally includea front panel adjoined to a back panel by one or more side panels tothereby form a continuous chamber. The continuous chamber of the massconfinement cell allows the flow of fill material to adjacent massconfinement cells below and above. The deterioration resistant massconfinement cell is generally a hollowed frame or shell of adeterioration resistant material that is light-weight and is configuredto interlock with adjacent confinement cells, thereby forming acontinuous chamber system capable of accepting and retaining any type offilling material. The filling material provides weight, density,structure and stability to the retaining wall cells and also ultimatelyprovides stability and security to the retaining wall constructed ofsuch cells.

As previously mentioned, various embodiments of the deteriorationresistant mass confinement cells of the present invention comprise afront panel, back panel and one or more side panels, which adjoin thefront panel and back panel thereby forming a confinement cell having acontinuous flow chamber. In various embodiments at least two of the sidepanels extend from the front panel to the back panel at angles (e.g.less than) 90°, thereby allowing for a back panel that is of shorterlength than the front panel. The shorter back panel allows the productto produce curves in retaining walls or revetments. Additionally, thecontinuous flow chamber of these mass confinement cells generally formsa series of integrated channels when placed in a wall or earth retentionstructure, thereby allowing the flow of fill material between adjacentconfinement cells.

The cells of the present invention may further include one or moreanchoring devices for securing each cell to adjacent cells or securingthem into position in the retaining wall. In various embodiments of thepresent invention one or more of the panels include one or more pegextensions or locking extensions for interconnecting the stackedconfinement cells. The peg extensions or locking extensions assist inpositioning and/or adjoining adjacent cells and facilitating the flow offill material to the adjacent cells. Additionally, the peg extensions orlocking extensions assist in retaining the fill material within theadjoined confinement cells and also may lock the adjacent cells to eachother. As previously suggested, the continuous chambers are adapted forreceiving and retaining fill materials, such as sand, dirt, gravel, pearock, class V, concrete or any other similar material, which providesthe permanent weighting and stability of each retaining wall cell.

In additional embodiments of the present invention, the cells maycomprise two or more separated panels that are adjoined by a securingmechanism, such as a “T-hook and T-slot”, or a “peg and socket system”.For example, the front panel, side panels and/or back panel may beseparate panels that are secured together to form the confinement cellsof the present invention. These embodiments provide the benefits ofproviding two or more substantially flat panels and/or nestable panelsthat may be assembled to form each cell. Also, such a process may openother beneficial manufacturing techniques to form such panels, such asextrusion, thermoforming and vacuum forming. Such embodiments will alsogenerally provide benefits related to transportation and storage in thatthe various components nest and/or may be transported in relatively flatpanels.

Embodiments of the deterioration resistant mass confinement cells of thepresent invention may be used in constructing retaining walls and earthretention systems on a number of property terrains, such as alongwaterfront properties or along gradual or steep embankments. Thedeterioration resistant confinement cells are particularly useful forterrains near water or underwater due to their resistance todegradation. However, the deterioration resistant cells could also beused for land applications for those that want a light-weight retainingwall product that can be filled on-site to add weight and stability andalso does not require heavy equipment for moving and installing.Therefore, the deterioration resistant mass confinement cells could beutilized to construct any form of wall, earth retention system or fencestructure.

One unique feature of the present invention is the lightweightcharacteristic of each confinement cell before it is filled and thestable and weighted characteristic after it is filled. As previouslymentioned, embodiments of the present invention may be filled with anytype of fill material located at the site, such as rocks (e.g. crushedrock and pea rock), sand, gravel, soil, concrete or similar materials.The filling characteristic of the deterioration resistant confinementcells means that when the cells are not filled they are verylight-weight. This light-weight feature provides individualsconstructing such walls the advantage of easily moving large numbers ofthe confinement cells to the site of construction with relative ease.Furthermore, the lightweight characteristic of such cells allows foreasy maneuvering of the cells into final position when constructing aretaining wall or revetment, but still allows for the stability as foundin heavy concrete products when these same confinement cells are filled.These characteristics are met by each mass confinement cell being madeof a lightweight material, such as plastic (e.g. high densitypolyethylene), and by it also being configured to receive a heavy fillmaterial once it has been placed in its final position on the retainingwall.

Individuals would be more inclined to install products made of adeterioration resistant material, rather than cement block, timbers, drycement process (or dry-cast) block (e.g. Keystone® or Anchor® block) andthe like, because of their installation ease attributed to thelight-weight properties and enhanced longevity. The weight of mostregular retaining wall block is approximately 12-120 lbs, whereasembodiments of the present invention are approximately 2-20 lbs. Ofcourse, weight may vary depending on the size and materials utilized inmanufacturing embodiments of the present invention.

Embodiments of the present invention are also superior to otherretaining wall products due to the precise nature of the materials andmanufacturing processes. Such processes generally exhibit minimal to nodifference in unit dimensions and feature characteristics, therebyallowing for precision in product specifications and building structureswith such units. Examples of possible manufacturing methods include butare not limited to injection-molding, structural foam molding (e.g. lowpressure multi-nozzle structural foam), extrusion, roto-molding,thermoforming, vacuum forming and blow-molding. However, it is notedthat any high volume application for production may be utilized inmanufacturing the present invention.

The individual units of the present invention are light-weight,aesthetically pleasing, easy to install, prevent shoreline and otherterrain erosion and compliment preexisting retaining wall products.Various embodiments of mass confinement cells of the present inventionare also waterproof and/or absorption resistant, can withstand icedamage due to their flexible nature and are easily replaced or repairedin case of damage. Furthermore, the confinement cells of the presentinvention are rugged and require very low maintenance. Additionally,embodiments of the present invention are easily transportable, storableand installable due to their light-weight and possible stacking and/ornesting features.

As previously suggested, embodiments of the present invention are alsoresistant to deterioration, such as wear, discoloration, crumbling andbreaking. Therefore, the deterioration resistant mass confinement cellsdo not have to be replaced as often and/or increase the lifespan of theretaining wall or earth retention system. Due to these characteristics,the cells of the present invention generally have a much greaterlifespan than the life of a regular dry-cast concrete type block ortimber. The increased lifespan of the confinement cells translates tofewer or no occurrences of replacement of individual cells or thepotential complete reconstruction of the entire wall. Furthermore,retaining wall materials, such as concrete block formed by the dry castprocess, (e.g. Keystone® blocks) and timbers are typically not used inwater applications because they dissolve, crumble and/or break down overtime and exposure. The durability and deterioration resistantcharacteristics of the present invention reduce and prevent thestructural degradation of the product, thereby making it very beneficialfor all applications that come in contact with water.

Another advantage of embodiments of the present invention relates to thehigh cost of waterfront property and people's inclination to improvetheir property to keep it well-maintained and aesthetically pleasing. Aspreviously mentioned riprap, is commonly stacked along propertyshorelines to prevent erosion. The trouble with this shorelinepreservation application is that rip rap is generally heavy, therebymaking it difficult to install. Furthermore, rip rap will generallyleave many crevices for organic material to reside and, since it isclose to water, the crevices are prominent areas for the growth ofvegetation. In addition, many waterfront properties suffer water damagewhen water levels rise above the shoreline. The mass confinement cellsof the present invention are a solution to water retention and erosionproblems in such areas of threatening high or rising water levels.Furthermore, the mass confinement cells pose a solution in locationswhere there is a flood plane or areas that are washed out by any type ofwater movement. Sandbags have been a solution to such problems, but arenot a permanent or aesthetically pleasing solution. The retaining wallcells can replace sand bags in an area for which a more permanent andaesthetically pleasing alternative is desired.

As previously suggested, the deterioration resistant mass confinementcells can be produced in any type of shape, configuration, color anddesign. In addition each confinement cell may include any design orcolor located anywhere on one or more panels or walls of the confinementcell.

In summary, the utilization of conventional type materials for retainingwalls, such as concrete blocks (wet or dry cast), timbers, rip rap andother wall or revetment construction materials, have caused problemsrelated to their inherent weight, deterioration tendencies and aestheticdeficiencies. Therefore, the present invention provides an aestheticallypleasing, durable and easy to use product for all persons intending toconstruct a retaining wall or earth retention system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a front perspective view of one embodiment of adeterioration resistant mass confinement cell.

FIG. 1 b is a front perspective view of an embodiment of a deteriorationmass confinement cell with a beveled front panel.

FIG. 2 a is a front perspective view of an embodiment of a massconfinement cell having a T-slot securing mechanism.

FIG. 2 b is a front perspective view of an embodiment of a partial massconfinement cell having a peg and socket securing mechanism and an innerpartition.

FIG. 2 c is a front perspective view of an embodiment of a massconfinement cell having an integral peg and socket securing mechanism.

FIG. 3 is a front perspective view of an embodiment of a deteriorationmass confinement cell including a peg and socket securing mechanism andintegral back and side panels.

FIG. 4 is a back perspective view of an embodiment of a deteriorationresistant mass confinement cell including a peg and socket securingmechanism and integral back and side panels.

FIG. 5 is a front perspective view of an embodiment of a front panel ofa deterioration resistant mass confinement cell.

FIG. 6 a is a perspective view of an embodiment of a deteriorationresistant mass confinement cell including a peg and socket securingmechanism.

FIG. 6 b is a perspective view of the Detail A peg and socket securingmechanism of FIG. 9 a.

FIG. 6 c is a perspective view of the Detail B peg and socket securingmechanism of FIG. 9 a.

FIG. 7 a is a back perspective view of one embodiment of a stabilizingpartition.

FIG. 7 b is a front perspective view of one embodiment of a stabilizingpartition.

FIG. 8 is an exploded front view of one embodiment of a deteriorationresistant mass confinement cell including integral side and back panels.

FIG. 9 is an exploded back view of one embodiment of a deteriorationresistant mass confinement cell including integral side and back panels.

FIG. 10 is a front perspective view of one embodiment of a deteriorationresistant mass confinement cell including integral side and back panelsand a stabilizing partition.

FIG. 11 a is a back perspective view of an embodiment of a back panelthat includes a locking peg extension.

FIG. 11 b is a front perspective view of an embodiment of a back panelthat includes a locking peg extension.

FIG. 12 is a front perspective view of one embodiment of a deteriorationresistant mass confinement cell including an interior partition.

FIG. 13 is an exploded front view of one embodiment of a deteriorationresistant mass confinement cell including an interior partition.

FIG. 14 is a back perspective view of an embodiment of a front panel ofa deterioration resistant mass confinement cell of FIG. 12.

FIG. 15 is a front perspective view of one embodiment of a deteriorationresistant mass confinement cell including two adjoinable frame sections.

FIG. 16 is a back perspective view of one embodiment of a deteriorationresistant mass confinement cell including two adjoinable frame sections.

FIG. 17 is an exploded front view of one embodiment of a deteriorationresistant mass confinement cell including two adjoinable frame sections.

FIG. 18 a is a front view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 18 b is a back view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 19 a is a front view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 19 b is a back view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 20 a is a front view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 20 b is a back view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 21 a is a front view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 22 b is a back view of one embodiment of a fascia that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 22 a is a perspective top view of one embodiment of an edger thatmay include the surface coating or lamination of the present invention.

FIG. 22 b is a perspective bottom view of one embodiment of an edgerthat may include the surface coating or lamination of the presentinvention.

FIG. 23 a is a perspective top view of one embodiment of a paving stonethat may include the surface coating or lamination of the presentinvention.

FIG. 23 b is a perspective bottom view of one embodiment of a pavingstone that may include the surface coating or lamination of the presentinvention.

FIG. 24 is a perspective view of one embodiment of a front panelincluding a partial top panel.

FIG. 25 is a perspective view of one embodiment of a front panelincluding a partial top panel having a planting aperture.

FIG. 26 is a perspective view of one embodiment of a front panelincluding a partial top panel and a plurality of securing mechanisms.

FIG. 27 is a back perspective view of an embodiment of a load cell thatmay be used with a deterioration resistant mass confinement cell of thepresent invention.

FIG. 28 a is a front view of one embodiment of an end cap that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 28 b is a back view of one embodiment of an end cap that may beutilized with the deterioration resistant cells of the presentinvention.

FIG. 29 is a front perspective view of one embodiment of a deteriorationresistant mass confinement cell of the present invention that includes aframe, load cell, fascia and end caps.

FIGS. 30 a-b are perspective views of two top cover embodiments used tocap a deterioration resistant mass confinement cell.

FIGS. 31 a-b are perspective views of two bottom cover embodiment usedto seal a deterioration resistant mass confinement cell.

FIG. 32 depicts an exploded perspective view of an embodiment of aninterlocking mechanism used with the deterioration resistant massconfinement cell that includes pegs and hinges.

FIG. 33 depicts a perspective view of an embodiment of an interlockingmechanism use with the deterioration resistant mass confinement cell ofthe present invention that is a clipping device.

FIG. 34 depicts a perspective view of an embodiment of an interlockingmechanism use with the deterioration resistant mass confinement cell ofthe present invention of the present invention that is an integral hook.

FIG. 35 depicts a perspective view of a plurality of deteriorationresistant mass confinement cells in nesting positions.

FIG. 36 depicts a perspective view of a plurality of nestabledeterioration resistant mass confinement cells without the front panelin nesting positions.

FIG. 37 depicts a perspective view of an embodiment of a deteriorationresistant mass confinement cell including a structural stabilizationgrid.

FIG. 38 depicts a perspective view of an embodiment of a plurality ofdeterioration resistant mass confinement cells adjoined to a cellularconfinement system.

FIG. 39 depicts a perspective view of an embodiment of a plurality ofdeterioration resistant mass confinement cells adjoined to a cellularconfinement system with a plurality of reinforcing members.

FIG. 40 a-b depict front perspective views of two retaining wallsconstructed with embodiments of the mass confinement cells of thepresent invention.

FIG. 41 depicts a front perspective view of one embodiment of a cell capthat may be utilized with various embodiments of the present invention.

FIG. 42 depicts an exploded view of one embodiment of a cell cap thatmay be utilized with various embodiments of the present invention.

FIG. 43 a is a perspective view of one top cap embodiment of the cellcap of FIG. 42.

FIG. 43 b is a perspective view of one top cover embodiment of the cellcap of FIG. 42.

FIG. 43 c is a back perspective view of an end cap embodiment of thecell cap of FIG. 42.

FIG. 43 d is a front perspective view of an end cap embodiment of thecell cap of FIG. 42.

FIG. 44 depicts a perspective view of one embodiment of a cell cap thatmay be utilized with various embodiments of the present invention.

FIG. 45 depicts a perspective view of one embodiment of a cell capincluding locking peg extensions that may be utilized with variousembodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments of the present invention described below are notintended to be exhaustive or to limit the invention to the precise formsdisclosed in the following detailed description. Rather, the embodimentsare chosen and described so that others skilled in the art canappreciate and understand the principles and practices of the presentinvention.

Various embodiments of the deterioration resistant mass confinement cell10 generally comprise a front panel 12, a back panel 14 and one or moreside panels 16 as depicted in FIGS. 1 a and 1 b. The side panels 16 ofthese embodiment operably join the front panel 12 and back panel 14 toform the confinement cell 10 having a continuous flow chamber 18. Thecontinuous flow chamber 18 is positioned within the front panel 12, backpanel 14 and side panels 16.

It is noted that various embodiments of the mass confinement cell 10 ofthe present invention include no top panel or a partial top panel and nobottom panel or a partial bottom panel. The assembly of a retaining wallwith a plurality of such confinement cells, which include an open topand bottom, allows for the flow and/or commingling of fill material fromadjacent cells positioned above and/or below through each cell'scontinuous flow chamber 18. In other embodiments, the bottom panel mayinclude one or more apertures to allow for at least a partial alignmentof openings, thereby allowing the flow and commingling of fill materialfrom one confinement cell to cells positioned above and/or below.

Additionally, the mass confinement cell 10 of various embodiments of thepresent invention may include two or more separated panels 12, 14, 16 orsections that are operably connected with one or more securingmechanisms 22 to join the two or more panels 12, 14, 16 or two or moresections (e.g. sections may be two or more panels that are integrallyadjoined without securing mechanisms), thereby forming the confinementcell 10. FIGS. 2 a-c depict three embodiments of the present inventionthat include panels 12, 14, 16 that are adjoined with securingmechanisms 22. In other embodiments, the mass confinement cells 10utilize securing mechanisms 22 to join three or more panels 12, 14, 16or sections to form the mass confinement cell 10. Also, in still otherembodiments, the mass confinement cells 10 of the present inventionutilize securing mechanisms 22 to join four or more separated panels 12,14, 16 or sections to form the confinement cell 10. In many of theseembodiments, the one or more side panels 16 are operably joined to thefront panel 12 and/or back panel 14 with two or more securing mechanisms22 to form a continuous flow chamber 18 within the mass confinement cell10.

It will be found that various mass confinement cell embodiments of thepresent invention are especially advantageous for mega-cell products ofsizes equal to or greater than one foot in height, two feet wide and onefoot deep (e.g. at least about 1.5 feet in height, 3 feet wide and 1.5feet deep). Such large confinement cells allow for easy storage andtransportation of such mega-cells by allowing them to flatten or nest,thereby decreasing the space needed for large numbers of cells.

In various embodiments of the present invention, the front panel 12 ofthe cell may be flat, rounded or beveled and are generally molded orfabricated (e.g. lamination, painting, U.V. Coating) to provide thedesired earthen appearance. FIG. 1 a depicts an embodiment of a cell 10with a flat front panel 12. FIG. 1 b depicts an embodiment of a cell 10with a beveled front panel 12. FIG. 2 a depicts an embodiment of a cell10 with a rounded front panel 12. However, it is noted that in otherembodiments a fascia may be secured to the front panel 12 to provide thedesired appearance. In various embodiments of the present invention, thefront panel or fascia may also be beveled, rounded, substantially flator include positions of relief to provide a more natural earthenappearance, such as stone or wood.

FIGS. 3 and 4 depict another embodiment of the mass confinement cell 10of the present invention wherein the cell 10 includes side panels 16 anda back panel 14 that are formed or manufactured in a single part orsection 24, thereby foregoing the need for one or more of the securingmechanisms 22 to secure the side panels 16 with the back panel 14. It isnoted that a section may be a combination of two or more panels, such asa back panel secured to one or more side panels or a front panel securedto one or more side panels. Such an embodiment has benefits in providingfor additional stability of the confinement cell structure and theability to manufacture the entire confinement cell 10 with a limitednumber of parts (e.g. two part system; a side/back section and a frontpanel or a side/front section and a back panel). Such embodiments allowfor the back and side panels 14, 16 to be formed in a single part byprocesses that have manufacturing benefits, such as injection molding,structural foam molding (e.g. low pressure multi-nozzle structuralfoam), extrusion or thermoforming. Once the single back/side orfront/side section 24 is provided, it may be adjoined to a molded and/orfabricated front panel 12 or a back panel 16 by securing the piecestogether with one or more securing mechanisms 22.

In various embodiment of the present invention, the front panel 12 ofthe cell 10 may be flat, rounded or beveled. For example, FIG. 5 depictsa front panel 12 of the cell 10 depicted in FIGS. 1 and 2. The frontpanel 12 of this embodiment includes a rounded front panel 12, but mayinclude a flat or a beveled front having one or more bends and/orslants. It is noted that the front panel 12 may also include positionsof relief or creases and clefts to provide a more natural appearance.

The front panel of this embodiment further includes a front plate 26 anda back plate 28 that are separated by one or more ribs 30 to adjoin andprovide support and stability to the front plate 26 and back plate 28.Alternatively, a corrugated or waved ribbing system (not shown) mayseparate the front plate 26 and back plate 28 rather than straight ribsto provide a pressure absorption means, thereby removing the pressureproduced by the fill material on the front panel 12. The front panel 12of this embodiment further includes at least part of one or moresecuring mechanisms 22. As will be explained further below, the frontplate 26 and/or front panel 12 generally will display an earthenappearance or other aesthetic design that may be molded into the surfaceor applied to the surface.

As previously mentioned, various embodiments of the mass confinementcell 10 generally include one or more securing mechanisms 22 thatprovide a sufficient means for securing the separated panels 12, 14, 16to each other. A sufficient means is generally one wherein the securingmechanisms 22 will not release when the force of the fill material isapplied to the panels 12, 14, 16 of the mass confinement cell 10. FIGS.6 a-6 c depict one embodiment of a securing mechanism 22 that may beutilized to form one embodiment of a mass confinement cell 10 of thepresent invention. FIG. 6 a depicts one embodiment of a mass confinementcell 10, wherein the confinement cell 10 includes a front panel 12 andback panel 14 adjoined to two side panels 16 with securing mechanisms22. FIGS. 6 b and 6 c depict one embodiment of a securing mechanism 22utilized to adjoin the panels 12, 14, 16 of the confinement cell 10 ofthe present invention. In this embodiment, the securing mechanism 22includes a peg and socket system including a peg 32 having a base 34 andtwo or more elongated keys 36 extending upward from the base 34. In someembodiments, the keys 36 may include a beveled top that allows for thekeys 36 to be inserted into a socket 38 and lock the panels 12, 14, 16into place when completely inserted.

Other embodiments of securing mechanisms that may be utilized in thepresent invention include the peg and socket systems (threaded,integrated and non-integrated) (See FIGS. 2 b-c), T-hook and T-slot (SeeFIG. 2 a), locking snaps and other mechanisms that would adjoin andsecure the panels into the confinement cell configuration. Examples ofsome securing mechanisms are disclosed or suggested in U.S. applicationSer. No. 11/126,546 filed on May 11, 2005, U.S. Provisional Application60/707,032, filed on Aug. 10, 2005, U.S. Provisional Application No.60/741,737 filed on Dec. 2, 2005 and U.S. Provisional Application No.60/777,617 filed on Feb. 28, 2006, the contents of which areincorporated by reference herein.

The various mass confinement cell embodiments may further include one ormore interior partitions 40. The interior partitions 40 may also beutilized to add additional support to the confinement cell 10 to preventany possible crushing or expansion of the cell 10. FIGS. 3 and 4 depictone confinement cell embodiment wherein the interior partitions 40 arewithin the interior of the cell 10 and are present to define separatechambers that can accommodate filling of each individual chamber 18 withappropriate fill material, such as sand, gravel, crushed rock, pea rock,soil, cement, concrete or any other suitable material. The interiorpartitions 40 may be secured to the front panel 12, back panel 14 or tothe two side panels 16 utilizing one or more securing mechanisms (e.g.peg and socket systems, T-hook and T-slot systems, panel slot systems,snap systems or any other securing means). Alternatively, the interiorpartitions 40 may be secured to the opposing panels utilizing otheradjoining means, such as screws, rivets, hooks, adhesives or any othermaterials to adequately adjoin the opposing panels.

FIGS. 7 a and 7 b depict interior and exterior views of one embodimentof an interior partition 40. The interior partition 40 of thisembodiment generally includes a sheet 42 having panel attachments 44 ateach end that can butt against and accommodate securing of the partition40 to a panel 12, 14, 16. As previously mentioned, any securing oradjoining means may be utilized to adjoin the interior partition 40 tothe front panel 12, back panel 14 or side panels 16. To furtherstabilize the interior partition 40, the partition 40 may also includeone or more ribs 28 that extend between the panel attachments 44 orextend from the top to the bottom of the interior partition 40 in avertical direction.

Additionally, multiple chambers 18 and partitions 40 also allow for themass confinement cell 10 to be cut into various shapes or into partialcells and still maintain a chamber 18 that can receive and retain fillmaterials. The ability to cut the retaining cells 10 and still retainthe same features is particularly useful in preparing ends and awkwardsegments of retaining walls. In one embodiment, a confinement cell 10,as depicted in FIGS. 3 and 4, may be cut to a desired width, andadjoined with a partition 40 positioned on the front panel 12 and backpanel 14 to thereby secure the front panel 12 to the back panel 14 ofthe cell 10 at approximately the points where they were cut.

FIGS. 8 and 9 depict exploded views of the mass confinement cell ofFIGS. 3 and 4, thereby illustrating the assembly of this embodiment ofthe present invention. In this embodiment, the front panel 12 includestwo sockets 38 that are adapted to accept two pegs 32 that are adjoinedto the two side panels 16. In some embodiments, the pegs 32 may bepolygonal in shape and the socket 38 circular in shape to thereby securethe front panel 12 to the remainder of the cell 10 when the pegs 32 areinserted into the sockets 38. Furthermore, one or more partitions 40 maybe positioned in the cell 10 to added additional stability to theconfinement cell 10 or to provide an outer panel when cutting.

The various embodiments of the present invention may also include one ormore pins 46 that may be inserted into apertures in the securingmechanism 22 or slots (not shown) positioned anywhere on the confinementcell to further secure the confinement cell 10 into position in aretaining wall and also may secure the confinement cell 10 to geo gridthat is positioned between rows of cells 10 when constructing a wall.FIGS. 8 and 9 depict one embodiment of the pins 46 that may be utilizedwith the cells of the present invention.

The various mass confinement cell embodiments of the present inventionmay further include one or more positioning flanges or settingextensions 48 as depicted in FIG. 9. On a constructed wall, eachretaining flange or setting extensions 48 are wall retention devicesthat operate to assist in placing the confinement cell in the properposition during wall assembly, and also inhibits outward movement of thewall once constructed. Normally, the retaining flange or settingextensions 48 extend downward from the back of the back panel 14 andrest against the back of the mass confinement cell or cells 10 locatedbelow. In other embodiments, the flange or setting extensions 48 mayalso extend downward from the front panel 12, side panels 16 or aninterior partition 40. FIG. 10 depicts one embodiment wherein thesetting extensions 48 extend downward from the partition 40. Theretaining flange or setting extension 48 may be a unitary pieceextending downward or upward from the mass confinement cell 10 or aseries of fingers extending downward or upward from the confinement cell10. It is also noted that the setting extensions 48 may further beutilized to anchor the confinement cell into the fill material below,thereby inhibiting movement of the cell upon filling.

FIGS. 11 a and 11 b depict another embodiment of an anchoring device andsecuring mechanism that may be utilized with various embodiments of thepresent invention. In this embodiment the one or more anchoring devicesare peg extensions 48 that may be utilized to position and secure eachcell 10 when assembling a wall and may also function to reduce orprevent overturn of the cells upon filling and compacting the fillmaterial. In this embodiment, the peg extensions 52 are positioned onthe back panel 14 are designed to fit in or under one or more pegextension slots or ridges (not shown) positioned on the two cells 10located below when constructing a wall, revetment or other earthretention system.

The back panel 14 of the embodiment of FIGS. 11 a and 11 b may alsoinclude ribs 30 that can be positioned on the front or back of the backpanel 14 to provide additional stability. In various embodiment when theback panel 14 is separated from the side panels 16, the back panel 14may include a securing mechanism 22 in the form of larger snaps 50 thatmay be inserted into apertures 52 positioned on the side panels 16.

In yet another embodiment of the present invention, a securing mechanism22 may be provided as a hybrid of a slot system and the peg and socketsystem. FIG. 12 depicts one embodiment of the present invention whereinan interior partition 40 includes the hybrid slot system and peg andsocket system to secure the front panel 12 to the side panels 16 andback panel 14. As depicted in the exploded view of FIG. 13, thepartition 40 includes two or more partition slits 54 to accommodate thesecuring of the two side panels 16 and back panel 14. The side panels 16also include one or more panel slits 56 that are inserted into the slits54 on the interior partition 40. One or more partition pegs 58 may bepositioned adjacent to the partition slits 54 on the interior partition40 and utilized to stabilize the partition 40 by positioning the pegs 58against side panel ridges 60 after assembly of the side panels 16 andback panel 14 to the interior partition 40. The side panel ridges 60prevent the partition 40 from rotating when assembly is complete. Thepartition 40 further includes one or more sockets 38 for receiving pegs32 positioned on the front panel 12 (as depicted in FIG. 14) whensecuring the front panel 12 to the rest of the confinement cell 10.

As depicted in FIGS. 10 and 12, the stabilizing partition 40 may beincluded in the mass confinement cell 10 to further stabilize the cellstructure, take pressure off of the front panel caused by the packedfill material and also provide a divider so that different fillmaterials may be added to the same cell 10 (e.g. a packing materialtoward the back of the confinement cell and a planting fill material inthe front of the cell). In some embodiments, as depicted in FIG. 10, thepartition 40 may include peg extensions 48 that operate as a cellpositioning and securing means when constructing a retaining wall. Thepeg extensions 48 may be placed anywhere on the partition 40 includingthe ends and/or dispersed along the bottom edge of the partition 40. Inconstruction of a wall, the peg extensions 48 may butt up against one ormore partitions present in blocks positioned below, thereby holding theconfinement cell 10 in position and providing an indication of properpositioning of the cell 10. It is noted that the peg extensions 48 maybe included on the front panel 12, back panel 16 or side panels 16rather than or in addition to the partition 40 so as to butt up againstthe front panel 12, back panel 14 or partitions 40 of the confinementcells positioned below.

FIGS. 15 and 16 depict another embodiment of the continuous chamber massconfinement cell of the present invention. The confinement cell 10 ofthis embodiment generally includes a frame comprising a top framesection 62 and a bottom frame section 64 that are adjoined with one ormore section fasteners 66. The confinement cell 10 of this embodimentfurther includes a fascia 68 adjoined to the front of the cell 10. Thefascia 68, in many embodiments of the present invention, is generallyadjoined with one or more fascia fasteners 70, including but not limitedto locking pegs, hooks, screws, rivets, adhesives, pins and the like.Generally, the top frame section 62 and bottom frame section 64 aresloped so as to allow each section and other top frame sections and/orbottom frame sections to nest within each other when disassembled toenhance transportation and storage efficiency. Finally, the confinementcell 10 of this embodiment may further include one or more retainingflanges or setting extension 48 for positioning and retaining each cellin the wall.

FIG. 17 depicts an exploded view of the mass confinement cellillustrated in FIGS. 15 and 16. In assembly, the top frame section 62and bottom frame section 64 are pushed together as shown until thefasteners 66 are engaged. Once the top frame section 62 and bottom framesection 64 are adjoined, the fascia 68 is secured by aligning the fascia68 with the front of the two sections 62, 64 and engaging the fascia 68to the sections 62, 64 with the fascia fasteners 70.

Other embodiments of the present invention may also include a fasciawith the desired aesthetic appearance, rather than having the aestheticappearance (e.g. texture and color) molded into the front face of thefront panel 12. FIGS. 18 a-b depicts a front view and back view of oneembodiment of a fascia 68 that may be utilized with any embodiment ofthe present invention. Generally, the fascia 68 includes a front surface72, a partial top panel 20 and one or more fascia fasteners 70. Thefascia 68 may also optionally include wrap around sides 74, that wraparound the side panels 16 and bottom panel upon assembly. The frontsurface 72, top panel 20 and wrap around sides 74 may be textured andinclude color and/or other additives (e.g. U.V. inhibitor) to providethe earthen appearance, a crystalline appearance or desired aestheticdesign. Additionally, the fascia 68 may be prepared utilizing any of thetechniques discussed below or those known in the art for forming thedesired appearance. FIGS. 19 a-b depict the front view and back view ofa fascia 68 of the present invention, wherein the fascia 68 alsoincludes a partial bottom panel 76. In all of the embodiments of thepresent invention that include a fascia 68, the fascia 68 may bepermanently fixed to the front panel 12 or may be removable so as to bereplaced when damaged or a change is desired. The fascia 68 may alsoinclude one or more indentations 78 for surrounding a load bearingmember (not shown) that is positioned on the front panel 12 andfunctions to support the load of the cells positioned above. These loadbearing members 204 are configured to take pressure off the fascia 254when a wall is assembled, thereby allowing for greater ease in removaland replacement when desired.

Another embodiment of a fascia 68 of the present invention is depictedin FIGS. 20 a and 20 b. These FIGS. depict a front and back view of oneembodiment of a fascia 68 that may be utilized with the confinementcells of the FIGS. described herein. Further explanation of fasciadesign and manufacture will be discussed below. The fascia 68 in variousembodiments of the present invention may include a plurality of ribs 30to add stability and structure to the fascia 68. It is noted that thetop panel 20 of the fascia 68 may include one or more indentations 78 toaccommodate and alternate between load bearing members 204 uponadministering the fascia 68 to the front panel 12.

FIGS. 21 a-b depict yet another embodiment of the fascia 68 that may beutilized with the confinement cells 10 of the present invention. Thefascia 68 generally includes a front surface 72, partial top panel 20,partial bottom panel 76, stability ribs 30 and two or more fasciafasteners 70. In this embodiment the fascia fasteners 70 include two ormore fascia keys 80 that are designed to flex enough to pass through andaperture in the front panel 12, thereby securing the fascia 68.

As previously suggested, the mass confinement cell embodiments depictedin previously disclosed FIGS. and the embodiments of the presentinvention are also especially advantageous for mega-cell products ofsizes equal to or greater than one foot in height, two feet wide and onefoot deep (e.g. approximately 1 feet in height, 2 feet wide and 1.5 feetdeep or 2 feet in height, 4 feet wide and 2 feet deep) and multi-cellproducts (e.g. products that appear like multiple individual units thatare approximately 3-36 in height, 2-4 feet wide and 9 inches to 4 feetdeep; see FIG. 20) that are advantageous for the mass consumer market.Such large confinement cells and multi-unit cells allow for easy storageand transportation of such mega-cells and multi-cells by allowing themto be transported or stored in flat or nested configurations. Suchconfigurations reduces the space needed for the transportation andstorage of large numbers of cells.

In various embodiments of the mass confinement cells 10 of the presentinvention, the surface visible to the observer, such as the front panel12 or fascia 68 of the mass confinement cell 10 will generally include amolded and/or fabricated texture and/or pattern in the deteriorationresistant material. In various embodiments of the present invention theexposed surface of the landscaping product, such as the front panel 12or fascia 68, will have a natural earthen appearance simulating thetexture and color of natural earthen surfaces. For example in someembodiments, the exposed surface of the front panel 12 or the surface ofthe fascia 68 may be textured and colored to have the appearance ofrock, natural stone, sand, soil, clay, wood, trees and foliage, water,or any other natural earthen appearance. In other embodiments, the frontpanel 12 or fascia 68 will have a crystalline appearance or will haveanother aesthetically appealing design. Additionally, in otherembodiments, the exposed surface of the landscaping product, such as thefront panel 12 or fascia 68, may further include one or more designs(e.g. symbols, company names, logos, images) that may be positioned inthe natural earthen appearance texture and color, crystalline textureand color or other design (e.g. a company logo embedded in a stone colorand texture). Also, in other embodiments of the present invention, thefront panel 12 or fascia 68 may further include a design, such as theappearance of multiple bricks, stones, or blocks. See FIG. 20 for anexample of a multi-stone design. This allows for the installation oflarger mass confinement cells (e.g. mega-cells) in a wall that appearsto include a multitude of bricks, stones, blocks, timbers and the like.

In various embodiments of the present invention the texture of the frontpanel 12 or fascia 68 is produced by imaging an actual natural surface,such as natural stone, brick or wood and producing a mold that mimicsthat particular image. The imaging of the natural surface can beperformed by processes such as casting the natural surface or by digitalscanning the natural surface. When casting the natural surface a mirrorimage of the surface can be produced by preparing a solidifyingmaterial, such as silicone, and casting it over the natural surface.Once the solidifying material sets the newly casted mold is removed andan opposite image or negative of the natural surface is produced. Oncethe casted mirror image is produced, a mold or a mold insertmanufactured from a suitable mold material, such as aluminum, steel or aceramic, can be produced for mass manufacture. In various embodiments ofthe present invention ceramic molds are produced to provide the desireddetail found in the natural surface which then can be transferred to amore durable steel or aluminum mold for mass manufacture. One source forsuch molds formed of ceramic materials is Arrow Pattern and FoundryCompany, 9725 South Industrial Drive, Bridgeview Ill. Alternatively, amold may be prepared by digitally scanning the natural surface, suchthat the surface of a stone, brick or piece of wood. Once scanned, amold can be produced from a suitable mold material for mass manufactureof the front panels or fascias having a front surface supporting thescanned image.

As previously suggested, many embodiments of the present invention havea molded or fabricated front panel 12, partial top panel (not shown),fascia 68 and/or other portions of the mass confinement cell 10 (e.g.endcaps and topcaps), that exhibit an earthen appearance, crystallineappearance or other aesthetic design. This may be accomplished in anumber of ways including but not limited to thermal molding, laminationand/or surface coating (e.g. U.V. activated coating or polymer adhesionpainting). For example, in some embodiments of the present invention thetexture and color of the confinement cell 10 may be formed by thermalmolding one or more resins that include colors and other additives in amold that has a desired texture. Such a process may be performed by anyprocess known in the art, such as thermoforming, extrusion, injectionmolding, structural foam molding (e.g. low pressure multi-nozzlestructural foam), vacuum molding or any combination thereof. Forexample, one or more polymers, such as HDPE, polypropylene or apolyester (e.g. Polyethylene terephthalate (PET), polycarbonate), thatincludes one or more colors, fillers, and/or additives (e.g. U.V.inhibitors) may be injected into a mold that includes a desired shapeand texture to form a front panel 12, fascia 68 or other visible part ofthe mass confinement cell 10. One example, of such a desirable materialthat may be utilized to produce components of the present invention bythermal molding is a bulk molding compound (BMC) or thermoset thatincludes one or more polyester resins, glass fibers and other additivesand is manufactured and/or molded by Bulk Molding Compounds, Inc. 1600Powis Court West, Chicago Ill. 60185 and Kenro Incorporated, a CarlisleCompany, 200 Industrial Drive, Fredonia, Wis. 53021. In variousembodiments, the texture may also be imprinted on the mass confinementcell 10, 210 310 in a secondary process after formation of one or morecomponents of the confinement cell 10, 210, 310 by rolling a die thatimprints the texture on the surface of the polymeric front panel 12,fascia 68 and/or other portion of the cell 10.

In other embodiments of the present invention, the earthen appearance orother design can be achieved through a lamination process. In variousembodiments, a sheet of polymeric material including the desired colorand additives (e.g. UV inhibitor, natural or synthetic stone particles .. . ) is laminated over the portions of the mass confinement cell 10that are intended to have the earthen appearance or other design. Invarious embodiments of the present invention a sheet of polymericmaterial may include natural or synthetic particles (e.g. granite,marble, aluminum trihydrate, aluminum oxide, calcium oxide . . . ).Generally, in the lamination process, the front panel 12 or fascia 68may have a sheet of polymeric material heat welded or adhered to thefront surface plastic of the front panel 12 or fascia 68. Such alamination step may happen in a secondary step after formation of thefront panel 12 or fascia 68. Alternatively, the lamination plastic sheetmay be inserted into the front side of a mold and formed over the resinthat is administered into the mold (e.g. in-mold decoration). Forexample, a sheet of polymeric material may be placed in the front end ofan injection molding mold and subsequently thermoformed or vacuum formedto the front surface of the mold prior to filling the mold with resinwhen manufacturing the front panel 12 or fascia 68. Next, melted resinis shot into the injection mold, thereby integrating the laminated sheetinto the face and optionally top of the front panel 12 or fascia 68.

In yet other embodiments of the present invention, the earthenappearance or aesthetic design may be achieved by utilizing a solidsurface coating. The solid surface coating generally includes one ormore natural mineral or fiber fillers, one or more polymeric binderresins and one or more initiators. The natural mineral or fiber fillersmay include but are not limited to natural stone or rock filler (e.g.granite, marble, quartz, limestone, shale particles), wood fiber,hydrated alumina (e.g. aluminum trihydrate), ground silica, acrylicchips, calcium carbonate, aluminum oxide with pigmented polymer coatedquartz, sand, and any other filler that would provide a natural earthenappearance.

Various embodiments of the present invention include one or morepolymerizable binder resins. In one embodiment, the present inventionprovides a system comprising initiators and one or more of thepolymerizable binder resins, each binder resin bearing one or morepolymerizable groups. In accordance with this embodiment, thephotoinitiator group serves to initiate polymerization of thepolymerizable groups, thereby forming a polymeric coating, e.g., in theform of a layer covalently bound to the support surface (e.g. blocksurface or landscaping product surface) of a desired article via the oneor more initiators. As used herein, “polymerizable group” shallgenerally refer to a group that is adapted to be polymerized byinitiation via free radical generation, and more preferably byphotoinitiators activated by visible or long wavelength ultravioletradiation.

Suitable polymerizable compounds are selected from monomericpolymerizable molecules (e.g., organic monomers), and macromericpolymerizable molecules (e.g., organic macromers). As used herein,“macromer” shall refer to a macromolecular monomer having a molecularweight of about 250 to about 25,000, and preferably from about 1,000 toabout 5,000. For purposes of the present invention, and unless specifiedotherwise, the term “monomer” when used in this respect shall generallyrefer to monomeric and/or macromolecular polymerizable molecules.

In yet another embodiment, the polymerizable monomer compounds of thepresent invention comprise macromeric polymerizable molecules. Suitablemacromers can be synthesized from monomers such as those illustratedabove. According to the present invention, polymerizable functionalcomponents (e.g., vinyl groups) of the macromer can be located at eitherterminus of the polymer chain, or at one or more points along thepolymer chain, in a random or nonrandom structural manner.

Examples of some polymerizable binder resins that may be utilized in thepresent invention include, but are not limited to, polyurethanes,polyepoxides, epoxy-acrylates, epoxide and epoxy resins, urethaneacrylates, methacrylates, unsaturated polyesters, polyols, acrylics andmonomers and oligomers having similar backbone structures of theseresins.

The coatings also include one or more initiators. Generally theinitiators are polybifunctional reagents of the invention carry one ormore pendent latent reactive (e.g. photoreactive or thermoreactive)moieties covalently bonded to the resin. Various embodiments of thecoatings of the present invention include one or more photoreactivemoieties that are sufficiently stable to be stored under conditions inwhich they retain such properties. Latent reactive moieties can bechosen that are responsive to various portions of the electromagneticspectrum, with those responsive to ultraviolet and visible portions ofthe spectrum (referred to herein as “photoreactive”) being particularlypreferred.

Photoreactive moieties respond to specific applied external stimuli toundergo active specie generation with resultant covalent boding to anadjacent chemical structure, e.g., as provided by the same or adifferent molecule. Photoreactive moieties are those groups of atoms ina molecule that retain their covalent bonds unchanged under conditionsof storage but that, upon activation by an external energy source, formcovalent bonds with other molecules.

The photoreactive moieties generate active species such as free radicalsand particularly nitrenes, carbenes, and excited states of ketones uponabsorption of external electric, electromagnetic or kinetic (thermal)energy. Photoreactive moieties may be chosen to be responsive to variousportions of the electromagnetic spectrum, and photoreactive moietiesthat are responsive to e.g., ultraviolet and visible portions of thespectrum are preferred and are referred to herein occasionally as“photochemical” moiety.

Photoreactive aryl ketones, such as acetophenone, benzophenone,anthraquinone, anthrone, and anthrone-like heterocycles (i.e.,heterocyclic analogues of anthrone such as those having N, O, or S inthe 10-position), or their substituted (e.g., ring substituted)derivatives are utilized in some embodiments of the present invention.The functional groups of such ketones are preferred since they arereadily capable of undergoing the activation/inactivation/reactivationcycle described herein. Benzophenone is one photoreactive moiety thatmay be utilized, since it is capable of photochemical excitation withthe initial formation of an excited singlet state that undergoesintersystem crossing to the triplet state. The excited triplet state caninsert into carbon-hydrogen bonds by abstraction of a hydrogen atom(from a support surface, for example), thus creating a radical pair.Subsequent collapse of the radical pair leads to formation of a newcarbon-carbon bond. If a reactive bond (e.g., carbon-hydrogen) is notavailable for bonding, the ultraviolet light-induced excitation of thebenzophenone group is reversible and the molecule returns to groundstate energy level upon removal of the energy source. Photoactivatablearyl ketones such as benzophenone, thioxanthone, camphorpyinone andacetophenone are of particular importance inasmuch as these groups aresubject to multiple reactivation in water and hence provide increasedcoating efficiency.

Other initiators may include one or more photoinitiated reagentsincluding four or more reactive groups. Examples of such initiatorsinclude tetrakis (4-benzoylbenzyl ether), the tetrakis(4-benzoylbenzoate ester) of pentaerythritol, and an acylated derivativeof tetraphenylmethane.

The azides constitute another class of latent reactive moieties andinclude arylazides (C6R5N3) such as phenyl azide and particularly4-fluoro-3-nitrophenyl azide, acyl azides (—CO—N3) such as benzoyl azideand p-methylbenzoyl azide, azido formates (—O—CO—N3) such as ethylazidoformate, phenyl azidoformate, sulfonyl azides (−SO2-N3) such asbenzenesulfonyl azide, and phosphoryl azides (RO)2PON3 such as diphenylphosphoryl azide and diethyl phosphoryl azide. Diazo compoundsconstitute another class of photoreactive moieties and includediazoalkanes (—CHN2) such as diazomethane and diphenyldiazomethane,diazoketones (—CO—CHN2) such as diazoacetophenone and1-trifluoromethyl-1-diazo-2-pentanone, diazoacetates (—O—CO—CHN2) suchas t-butyl diazoacetate and phenyl diazoacetate, andbeta-keto-alpha-diazoacetates (—CO—CN2-CO—O—) such as t-butyl alphadiazoacetoacetate. Other photoreactive moieties include the aliphaticazo compounds such as azobisisobutyronitrile, the diazirines (—CHN2)such as 3-trifluoromethyl-3-phenyldiazirine, the ketenes (—CH═C═O) suchas ketene and diphenylketene.

The solid surface coating may be applied to the surface of thelandscaping product of the present invention by any type of process thatwould provide substantial coverage of the product surface and secureattachment of the coating, such as spray coating, dip coating and thelike. In various embodiments of the present invention, the solid surfacecoating may be administered to the product surface in a one step ortwo-step process. For example, in a one step process, a substantiallyhomogenous mixture of the filler, polymerizable resin and initiators areadministered to the surface of the product and the initiators thensubsequently activated to polymerize the resin and attach the coating tothe surface.

Alternatively, a two step or grafting process may be utilized toadminister the solid surface coating. In such a process, the initiatoris first administered to the surface and activated to attach theinitiator to the surface. Once the initiator is attached, asubstantially homogenous mixture of the filler and polymerizable resinis administered to the surface and the initiator is again activated topolymerize the resin and attach the mixture to the surface. It is notedthat in various embodiments of the present invention, a tie-in layer maybe applied to the surface to facilitate better attachment of the solidsurface coating. For example, one or more layers, such as a silane,Plexar, Binel, siloxane and/or Parylene layer(s) may be applied to thesurface prior to administration of the solid surface coating.

In other embodiments of the present invention, the landscaping products,including the exposed components of the mass confinement cells (e.g.front panel, fascia, end cap, cell cap), may be colored and furthertextured utilizing a painting process. One such painting process thatmay be used with various embodiments of the present invention is apolymer adhesion painting process wherein a polymeric paint is adheredto the surface of the mass confinement cell 10 after the surface of thecell, such as the front panel 12, the fascia 68, the end cap 82 or thecell cap, has been flame treated or plasma treated. In one polymeradhesion painting method, the mass confinement cell is manufacturedutilizing a process, such as injection molding, structural foam molding(e.g. low pressure multi-nozzle structural foam), rotomolding,thermoforming, extrusion or any other process. Next, all surfaces of themass confinement cell intended to be painted are flame treated or plasmatreated with an ion gun prior to applying paint. The flame treating maybe performed with any gas torch system, such as propane, acetylene andthe like. Plasma treatment may also be performed by any device thatforms a gas plasma that can be directed to the polymeric surface. Theflame or plasma treated surface should be painted within 24 hours,optionally within 8 hours and further optionally within 5 hours. Oncethe surface has been flame or plasma treated, a polymeric paint, such asa polyurethane paint, is mixed with a crosslinker and applied to thesurface or surfaces of the mass confinement cell 10. It is noted thatthe polymer adhesion paint mixture should be applied shortly aftermixing; in some embodiments almost immediately. One example of the typesof polymeric paints that may be utilized with embodiments of the presentinvention is a two component polyurethane that generally includes a mixratio of five parts colored paint with one part crosslinker (e.g. XL-003crosslinker or an isocynate). Two examples of two such polyurethanebased paints are as follows:

Example 1

HIGH SOLIDS ALLPHATIC POLYURETHANE 120 Series DESCRIPTION High Solids3.5 V.O.C. two component polyurethane for metal, plastic, and interiorwood. It is used for industrial and automotive applications. This systemhas excellent chemical and stain resistance. It has shown excellentadhesion to many substrates with good mar and abrasion resistance and ithas 2-3 H hardness. CHARACTERISTICS Density-lbs/gal: 7.95-13.0 Solids,wt. %: 51-70 Solids, volume: 42.9-60   Viscosity:    35-42 Sec. FlashPoint ° F. 80 Application Method: Conventional of HVLP Reduction forApplication: 5-base; 1-XL009; 1-acetone  6-base; 1-XL003; 1-20LT161 PotLife:  3-HRS @ 70° F. Cure Schedule: 30 min @ 180° F. Gloss 60°: Flat to96 VOC as supplied-lbs/gallon: 3.0-3.6 VOC as applied-lbs/gallon:2.9-3.5

Example 2

MEDIUM SOLIDS ALLPHATIC POLYURETHANE 121 Series DESCRIPTION The 121Series is a medium solids, low temperature cure two componentpolyurethane for use on metal and plastic. It is used for industrial andautomotive applications. This system has excellent chemical, stain, andwater soak resistance. It has good adhesion to many substrates with goodmar and abrasion resistance and it has 2 H hardness. CHARACTERISTICSDensity-lbs/gal: 7.92-11.0 Solids, wt. %: 45-67 Solids, volume: 37-48Viscosity: 45 sec Zahn#2 Flash Point ° F. 78 Application Method: HVLP;Conv. Reduction for Application: 4-base; 1-XL009 5-base; 1-XL003 PotLife:   2 hrs @ 70° F. Cure Schedule: 35 min @ 160° F., Air Dry tackfree 40 min Gloss 60°: Flat to 96 VOC as supplied-lbs/gallon: 3.6-4.3VOC as applied-lbs/gallon: 3.37-4.0 Both polymer adhesion paints of Examples 1 and 2 are manufactured anddistributed by:

PRIME COATINGS 1002 Hickory Street Pewaukee, Wis. 53072

www.primecoatings.net

Telephone: (262) 691-1930

The polymer adhesion paints may be applied in any manner known in theart including, but not limited to, spraying, dipping, brushing, spongingand any other paint application method. In various embodiments polymeradhesion paint is applied by spraying. Generally, less than 40 mils ofpaint is applied to the surface intended to be painted. In otherembodiments less than 20 mils of paint is applied and in otherembodiments less than 10 mils of paint is applied to the surfaceintended to be painted. In one example, approximately 0.2 to 1.5 milsdry film thickness of base color was applied to the entire surface of afascia. Once the base paint has been applied, secondary colors mayoptionally be applied to the wet or dry base coat as desired. Suchsecondary colors may be applied in similar ways as the base paint, suchas spraying, dipping, brushing, sponging and any other spray techniqueknown in the art. It is also noted that a primer layer may be applied tothe substrate surface prior to applying the paints described herein. Forexample, a coating of binel, parylene or another primer coat may beapplied to the surface prior to applying the paint to promote optimumadhesion.

Once the paint has been applied to the desired surface of the massconfinement cells, the product is then cured. In various embodiments ofthe present invention, the product is oven cured following painting at atemperature of 220° F. and less (e.g. 175° F. to 220° F.); in otherembodiments 185° F. and less (e.g. 150° F. to 185° F.); and in stillother embodiments 160° F. and less (e.g. 100° F. to 150° F.). In variousembodiments the paint, is cured at the above mentioned temperatures fora period of 2 minutes to 4 hours; in other embodiments 5 minutes to 2hours and in still other embodiments 10 minutes to 30 minutes. Theproduct is then allowed to air dry. Once air dried, the mass confinementcell is ready for installation. It is noted that the curing process maybe performed at room temperatures, but the curing time usually will belengthened accordingly.

It is noted that the solid surface coating, polymeric sheet or polymeradhesion paint may be administered or laminated to any landscapingproduct comprised of a deterioration resistant material (e.g. plastic,fiberglass, etc.), such as landscaping edgers, stepping or patio stones,artificial rocks and boulders, mass confinement cell front panels andfascia and lawn furniture. In such embodiments, the solid surfacecoating, polymeric sheet or polymer adhesion paint is applied to one ormore surfaces of the landscaping products. FIGS. 22 a-b and 23 a-bdepict two embodiments of the landscaping products that may providesurfaces coated with the solid surface coating, polymeric sheet orthermal paint of the present invention. FIGS. 22 a and 22 b depict a topview and bottom view of an edger and FIGS. 23 a and 23 b depict a topview and bottom view of a stepping stone. In both of these embodiments,the surface exposed to the outside environment is coated with the solidsurface coating or polymeric sheet.

As previously indicated the mass confinement cells 10 of the presentinvention generally include one or more side panels 16 that engage andextend from the front panel 12 back to engage with a back panel 14. Asdepicted generally in a number of the FIGS., various embodiments of thepresent invention include side panels 16 engaging the front panel 12 atangles to provide for a tapering of the confinement cell as it movesback in width. The angle formed between the front panel 12 and sidepanel 16 is generally less that 90° when the front panel 12 issubstantially straight and less than 150° when the front panel 12 isrounded or beveled. In other embodiments, the angle is between about 45°and 85° for substantially straight front panels 12 and between 60° and110° for beveled and rounded front panels 12. In various embodiments theside panels 16 may extend from the front panel 12 at angles that wouldallow them to engage each other at the back of the confinement cell,thereby forming the back panel 14 and chamber 18 by their engagement(e.g. a triangle or diamond configuration). Finally, in variousembodiments, the top edge of the side panels 16 may slightly slope downfrom front to back, thereby providing a back end of the confinement cellthat is slightly lower than the front of the confinement cell (e.g.0.5-10 mm).

Furthermore, the side panels 16 may further include one or more gridfasteners (not shown), wherein geogrid can thread over and secure whenutilized between rows of confinement cells 10. In other embodiments, thegrid fastener may include an overhanging portion (not shown) that thegrid can slide under, thereby inhibiting vertical movement of the gridonce in position. The side panels 16 may further include lighteningapertures (not shown). Such apertures allow for reduction of resin andthereby make the product more light-weight and cost efficient.

In various embodiments of the present invention, the mass confinementcell 10 further includes a partial top panel that extends from the frontpanel 12 or fascia 68 that is exposed when a retaining wall isconstructed. The partial top panel assists to close or partially closethe top front portion of the confinement cell 10 that may be exposed tothe outer environment. In various embodiments, the mass confinementcells 10 include a partial top panel that extends from the front panel12 or fascia 68 back to no more than 75% of the depth of the confinementcell 10. It is noted that cell depth is measured from the front panel 12or fascia 68 to the back panel 16 of the confinement cell 10. In otherembodiments of the present invention, such a partial top panel extendsfrom the front panel 12 or fascia 68 no more than 50% of the depth ofthe confinement cell. In yet other embodiments the partial top panelextends from the front panel 12 or fascia 68 no more than 35% of thedepth of the confinement cell (e.g. 5% to 30%). Such a partial top panelprovides for at least a partial sealing of the confinement cell at thetop front portion, of which may be exposed when the retaining wall isconstructed in a configuration wherein the wall inclines back toward thesurface or slope intended to be protected. FIG. 24 depicts oneembodiment of the present invention wherein the front panel includes oneembodiment of a front panel 12 with a partial top panel 20. It is notedthat in various embodiments the top panel may further include one ormore planting apertures 94 (e.g. see FIG. 25) that may allow plantgrowth from the top surface of the confinement cell 10. As previouslysuggested, the open top and bottom of each mass confinement cell 10allows for the receiving and commingling of fill material that may flowfrom and through the confinement cell 10 to one or more adjacent cells10 below or above.

The partial top panel may further include optional top side panels 96that extend downward from the partial top panel and may extend over orwithin the side panels of the confinement cell (not shown). Also,various embodiments, as depicted in FIG. 26 may also include more thantwo securing mechanisms 22 positioned at various positions in the frontpanel 12. This is advantageous if partial cells are required. Forexample, the confinement cell 10 may be cut and a peg of the side panel16 may be secured into the additional socket of the securing mechanismof the front panel to secure the front panel 12 to the rest of theconfinement cell 10. By providing additional securing mechanisms 22, thecutting of the front panel 12 still allows for the remaining portion ofthe front panel 12 to have two outer securing mechanisms 22 for securinga side panel 16 to the cut front panel 12. Partial confinement cells 10may further include one or more shorter stabilizing partitions to assistin securing the two halves of the cell together and further stabilizingthe confinement cell 10 after cutting.

It is noted that in some embodiments, the partial top panel 20, asdepicted in FIGS. 24-26 may extend back from the top edge of the frontpanel 12 to the top edge of a partition 40. Therefore, an example ofsuch an embodiment would provide for a partial top panel 20 extendingfrom the front panel 12 to the partition 40 on the mass confinement cellof FIG. 10. In some embodiments, ribbing or inner stability ridges (notshown) may be positioned between the front panel 12 and partition 40 toprovide additional stability to the structure.

Also, in various embodiments, two or more of the panels may be adjoinedto other panels of the cell with living hinges. Living hinges generallycomprise a thin flexible plastic (e.g. HDPE, polypropylene) that canbend into position without breaking when the panels are formed into anassembly position to form the chamber.

It is further noted that the mass confinement cell embodiments mayfurther include a load cell 98 positioned within the front panel 12,side panels 16 and optionally a back panel 14. A further description ofload cell embodiments is described below. Such load cells positioned inand/or attached to the confinement cell 10 may be added to provideadditional structural support to the cell. FIG. 27 depicts oneembodiment of a load cell 98 that may be secured to the confinement cell10 by one or more load cell fasteners 100. Generally, the load cell 98is a cylinder that when attached to the confinement cell 10 forms and/orresides within the continuous chamber 18. In this application a cylindermay comprise a cylinder that includes a circular or elliptical structureand may also include a structure that has one or more substantiallystraight sides and one or more rounded sides. In the embodiment of FIG.29 the load cell 98 includes a substantially straight back panel 14integrally adjoined to a rounded front section 102. The back panel 14may further include ribs 30 that may be position on the front and/orback of the back panel 14 to provide additional stability. The load cell98 may further include an anchoring ridge 104 or aperture (not shown)that may be utilized to accept the anchoring devices for confinementcell 10 positioning and overturn prevention or reduction.

The load cell fasteners 100 may be any fastening device or material thatsecurely adjoins the load cell 98 to the confinement cell 10. In oneembodiment, as depicted in FIG. 29 the load cell fastener 100 is one ormore projections that extend inward from the outer edge of the anchoringridge 104. In operation, the load cell 100 is inserted into one or moreapertures in the confinement cell 10 so that the load cell fastener 100engages with a load cell aperture (not shown) or ridge on the sidepanels 16.

The load cell may further include one or more grid fasteners 106 forsecuring and positioning geogrid when it is utilized in a wallstructure. The grid fastener 106 is configured to be inserted in anaperture of the geogrid and positioned over the geogrid at connection sothat the grid does not move in a vertical direction once it is applied.

In some embodiments of the confinement cells 10 of the presentinvention, a plurality of load cells 98 may be adjoined together andsecured to the larger frame of the cell to reduce the flow forces of thefill materials in the larger walls. The load cells of the multi-loadcell embodiments may be adjoined with tabs that may be separated tocurve the wall when desired. Furthermore, the multi-cell embodiments ofthe present invention may be utilized to install large sections of wallwith few components and still provide the appearance of a multitude ofindividual cells.

Additionally, in other embodiments, the load cell may be splitvertically in two or more sections, wherein one section nests with theother section. The two nested sections allows for the compression of thesections together to make a smaller load cell that may be utilized whensecured to a cut confinement cell for partial confinement cells. In suchembodiments, the two sections would further include a fastening deviceto fixedly secure the two sections together when the proper size isachieved, thereby preventing movement of the two sections of the loadcell.

The mass confinement cell 10 of the various embodiments of the presentinvention may further be fitted with an end cap 82 to finish the end ofa wall, provide an end finish for a sharp turn (e.g. 90° turn) in thewall or to accommodate a partial confinement cell when a confinementcell must be cut for fitting. A front and back view of one embodiment ofan end cap 82 is depicted in FIGS. 28 a and 28 b. In most embodiments,the end cap 82 will include a back surface 84 and side surface 86 thatis textured and colored similar to the front panel 12 or fascia 68 ofthe mass confinement cell 10. Additionally, the top surface 88 of theendcap 82 may include a texture and color similar to the front panel 12or fascia 68 of the mass confinement cell 10. In one embodiment, asdepicted in FIG. 28 b, the end cap 82 includes one or more securing pegs90 that may be inserted into lightening apertures (not shown) or otherattachment points positioned in the side panels 16 of a confinement cell10. The end cap 82 may also include ribs 30 to provide stability to thestructure. FIG. 29 depicts one embodiment of a fully assembled massconfinement cell 10 that includes end caps 82. The embodiment of FIG. 29includes a front panel 12 having load bearing members 92, back panel 14,side panels 16, fascia 68 and two endcaps 82.

FIGS. 30 a-b and 31 a-b depict various embodiments of top covers 108 andbottom covers 110, which are configured and adapted to securely fit overor under embodiments of the mass confinement cell 10 of the presentinvention. Generally, in some embodiments, the top covers 108 and bottomcovers 110 utilized in constructing some of the retaining walls of thepresent invention are at the very top of the wall and very bottom of thewall to at least partially seal the continuous chamber channels.However, the use of such covers 108, 110 at intermediate locationsthrough the wall may also be performed. In various embodiments of thepresent invention, the top cover 108 generally includes a continuous toppanel 112 that includes optional overlapping edges 114, which overlapsecurely over the outside side and back panels 14, 16. In someembodiments of the invention, the overlapping edges 114 may be presentaround the entire perimeter of the top of the confinement cell 10.Alternately, a forward extending apron 116 may be positioned at thefront of the top cover 108 and utilized to secure the cover 108 to theadjacent confinement cell 10 below by inserting the apron 116 under thepartial top panel of the cell 10 below.

Embodiments of the bottom covers 110 of the present invention, asdepicted in FIGS. 31 a-b, may include a bottom panel 118 with attachedbottom side walls 120 extending around the perimeter of bottom of thecell. The side walls 120 may be configured to overlap the front, backand side panels 12, 14, 16 or configured to nest within the front, backand side panels 12, 14 and 16. In other embodiments, as depicted in FIG.31 a, the overlapping sides may include an optional channel 122 forreceiving and retaining the front, side and back panels 12, 14, and 16of the adjacent confinement cell 10 above. Alternatively, the top covers108 and/or bottom covers 110 may include only a top panel 112 or bottompanel 118 that nest and optionally secure into place just within thefront panel 12, back panel 14 and side panels 14 of the confinement cell10. Additionally, the top cover 108 may include one or more plantingapertures (not shown) for allowing the growth of vegetation from themass confinement cell.

FIGS. 32-34 depict other embodiments of the present invention whereinthe mass confinement cells 10 include an interconnecting device 124. Itis noted that in the mass confinement cell 10 embodiments, theinterconnecting device 124 may be a securing mechanism as describedabove or a variation thereof. In various embodiments, as depicted inFIG. 32 the interconnecting device 124 includes a peg and socket systemhaving one or more insertable pegs 32 to adjoin two or more confinementcells by inserting the pegs 32 into a socket 38. The sockets 38 aregenerally positioned on an edge or just inside the edge of the front,side and/or back panels 12, 16, 14. The sockets may be integral to thefront or back panels 12, 14 or may be secured to the panels 12, 16, 14in any manner known in the art. The pegs 32 are configured to besecurely receivable by the sockets and may be configured to swivel theconfinement cell 10. The insertable pegs 32 can be made of any shape andsize, which can be securely fit into the sockets.

Alternatively, in one embodiment of the present invention side by sideadjacent confinement cells 10 may be adjoined with a clipping device126. In one embodiment the clipping device 126 may be configured in a Ushape and sized to snuggly fit over the side panels 16 of two adjacentconfinement cells. An illustration of one embodiment of a clippingdevice is depicted in FIG. 33.

FIG. 34 depicts an additional embodiment of the present invention,similar to hook attachments, wherein the mass confinement cell 10includes an interlocking feature that comprises a hook or peg 128. Anoptional pocket (not shown) may also be placed in the confinement cell10 for receiving the hook 128 from adjacent confinement cells 10. Insuch an embodiment one or more hooks or pegs 128 extend from one sidepanel 16 of a mass confinement cell 10 and may be inserted over theopposite side panel 16 of an adjacent cell 10. Such interlockingmechanisms provides for a overall secure retaining wall structure byreducing the amount of movement that may occur during filling withunsecured individual cells.

Another advantage of certain embodiments of the mass confinement cellsof the present invention is that they also allow for easy storage andtransport due to the stackable capabilities present. For example, massconfinement cell are easily transported and stored by nesting the cellswithin each other or by separating the front panel 12, back panels 14and/or side panels 16 and stacking and/or nesting the respective panelswhen in transport or storage. FIG. 35 depicts a plurality of cell thatare nested and FIG. 36 depicts a plurality of partial mass confinementcells 10 that do not include an attached front panel positioned in anested position. Other nesting positions or stacked positions may alsobe utilized with various embodiments of the present invention.

The mass confinement cell 10 of the present invention may also beutilized with other wall stabilizing products to secure and stabilize astructure constructed of such cells 10. For example, FIG. 37 depicts anembodiment of a mass confinement cell 10 wherein a structural grid 130is attached to confinement cell 10 (e.g. attachment to the upper frontpanel 12, back panel 14, partial top panel 20, or bottom panel (notshown) or peg extensions 48 on the back panel 14 or partition 40. Thegrid 130 is buried behind the wall constructed of the confinement cellsof the present invention and acts to support and stabilize the aggregateplaced behind the wall and prevent the wall from moving forward awayfrom the embankment it is protecting.

In an alternative embodiment, the mass confinement cell 10 may beutilized with and/or secured to a cellular confinement system or blockconfinement system (e.g. A commercially available system is the Geo-web®plastic web soil confinement system or the Geo-block® system, sold byPresto Products, Incorporated, P.O. Box 2399, Appleton, Wis. 54913)thereby providing a retaining wall front to an erosion controlstructure. Suitable cell confinement systems are well known in the artand are generally disclosed in U.S. Pat. No. 6,296,924, issued on Oct.2, 1001, U.S. Pat. No. 5,927,506, issued on Jul. 27, 1999, U.S. Pat. No.5,449,543, issued on Sep. 12, 1995 and U.S. Pat. No. 4,778,309, issuedon Oct. 18, 1988, the entire contents of which are incorporated byreference herein.

In various embodiments of the present invention, a plurality ofconfinement cells 10, and/or multiunit confinement cells or partialcomponents of the cells 10 may be positioned upon a base of blockconfinement systems, such as Geo-block®, and/or operably secured to oneor more cell confinement systems, such as Geo-web®. The intermingling ofthe confinement cells 10 of the present invention with the cell or blockconfinement systems provides further stability to a retaining wallstructure, as well as allows for the construction of an aestheticallypleasing wall.

FIG. 38 depicts one embodiment of the present invention wherein aplurality of partial confinement cells including a front panel 12adjoined to two side panels are positioned adjacent to and adjoined to acell confinement system 132 with a cell confinement fastener 134. Thefront panel 12 may further include a partial top panel 20. In variousembodiments the front panel may be adjoined directly to the cellularconfinement system (not shown). In the embodiment depicted in FIG. 38,the front panel 12 and side panels 16 are positioned in front of one ormore cells of the front cellular wall of a cell confinement system 132and secured. If side panels are present the side panels may be securedto one or more cells of the cellular confinement system. The securing ofthe front panel 12 and/or side panels to the front cellular confinementsystem 132 may form a chamber that may be filled with one or more fillmaterials.

In various embodiments, the cell confinement fastener 134 may be anyform that extends from one or more panels 12, 14, 16 and over, under orthrough the front of the cellular confinement system 132 to thereby holdthe panel(s) 12, 14, 16 in position. For example, in one embodiment, asdepicted in FIG. 38, the front panel 12, side panels 16 or back panel 14may be secured to the cell confinement system 132 by one or more U-typeclips that extend from the front panel 12, side panels 16 or back panel14 between two layers of cell confinement systems 132 and up, downand/or through a cell of a cell confinement system 132 to secure theconfinement cell 10 to the cell confinement system 132. In otherembodiments, pegs may be used to secure the partial cells 10 to the cellconfinement system 118 by inserting a peg into threads that extend fromthe cell 10 and over the front face of the front of the cellularconfinement system 132. Other examples of cell confinement fasteners 134may include any securing mechanism, such as tabs, hooks, clips, cables,rods and the like.

Another cell confinement fastener 134 may further include one or morereinforcing members 136, such as cables, tendons and/or bars. Examplesof such reinforcing members are disclosed in U.S. Pat. Nos. 5,449,543and 5,927,906, the entire contents and description of which areincorporated by reference herein. In such embodiments, as depicted inFIG. 39 the reinforcing members 124 may be tendons that extend throughthe cellular confinement system 132 to secure the confinement cells 10.The reinforcing members 136, such as tendons, may also be extendedthrough the side walls 16 of the confinement cells 10 to secure adjacentcells 10 to each other. In such embodiments, reinforcing members 136that extend through the side walls 16 of the cells 10 may be intersectedand adjoined to tendons that extend through the cellular confinementsystems 132. Such intersection and adjoinment may be secured withfasteners 138 such as clips, wire or the fasteners disclosed in U.S.Pat. Nos. 5,449,543 and 5,927,906. The cells 10 and cellular confinementsystems 132 may also be further secured and reinforced with fastenersand securing rods as described in U.S. Pat. Nos. 5,449,543 and5,927,906.

As previously mentioned, the mass confinement cells of the presentinvention may be manufactured from a deterioration resistant,substantially rigid composite or polymeric material including, but notlimited to, plastic (e.g. recycled or virgin), thermoset, a rubbercomposition, fiberglass, or any other similar material or a combinationthereof. Preferable materials comprise light-weight and slightlyflexible polymers, such as high and low density polyethylene orpolypropylene or thermosets, such as the polyester bulk molding compoundproduced by BMC, Inc. However, other plastics and thermosets may also beused. Examples of other plastics include, but are not limited topolypropylene, acrylonitrile-butadiene-styrene (ABS), Polyethyleneterephthalate (PET), polycarbonate, poly(butylene terephthalate) (PBT),poly(cyclohexanedimethylene terephthalate) (PCT), styrene-acrylonitrilecopolymers (SAN), polyesters, polystyrene, polyvinyl chloride (PVC),polyurethane, copolymers including one or more of the previouslymentioned polymers and combinations thereof. It is also noted that thedeterioration polymeric materials may also be utilized with fillermaterials or recycled filler materials, such as titanium, carbon fibers,nylon, talc, glass, saw dust or paper byproducts, plastic and the like.Generally, the embodiments of the present invention may comprise anytype of material that would have the similar characteristics to plastic,vinyl, silicone, fiberglass, rubber or a combination of these materials.It is noted that the material utilized in the present invention shouldbe rigid enough to hold its form upon addition of filling material andalso when placed in contact with other objects. Also the panels of themass confinement cells should be substantially non-collapsible when in afilled and stacked state. Another material that may be utilized to formthe components of the present invention may be comprised of a materialsimilar to that utilized in the production of some types of garbage cansor the utilization of recycled rubber from objects such as tires. Suchmaterials would be capable of holding rigidity and still offerflexibility when placed in contact with other objects, such as ice.Also, such materials have the ability to regain its original form whenthe object or material has been removed.

Embodiments of the present invention may also vary in appearance. Sinceembodiments of the present invention may be manufactured by a processsuch as injection molding, structural foam molding (e.g. low pressuremulti-nozzle structural foam), extrusion, thermo-forming, compressionmolding, roto-molding and the like, the molds may include any type ofdesign or shape. Furthermore, the front panels of the mass confinementcell 10, could be molded in almost any type of configuration. In oneembodiment, multiple mass confinement cells 10 could be molded toinclude designs that, when positioned on a retaining wall, wouldcomplete a larger single design, such as the spelling of a company orschool name in large letters or the completion of a large image. Also,since the present invention may be manufactured from and/or include anumber of different products, such as plastic, a rubber composition orfiberglass, and may include any color or a multitude of colors. Forexample, a retaining wall installed in a beach setting may bemanufactured of a plastic or rubber product and be colored in so thatorganic matter wash up on it would not show up as readily or may take onthe appearance of sand.

Additionally, in various embodiments of the present invention, one ormore lighting devices may be incorporated into the mass confinementcells of the present invention. For example, lighting devices (e.g.Light Emitting Diodes (LEDs), halogen lights, fluorescent lights,incandescent lights) may be attached to the frame, pass through theframe or attached to the front or back surface of the fascia. Suchlighting devices, when lit, will illuminate the front panel of the frameand/or the fascia. Any power source may be utilized to power thelighting devices. Examples of power sources that may be utilized withthe mass confinement cells of the present invention include, but are notlimited to, batteries, conventional electrical circuits and wiring,solar, wind or any other source that would provide the requisite powerto light the lighting device. In some embodiments, solar panel lightingfixtures are affixed or pass through the front panel of the frame,thereby positioning such lighting fixtures between the frame and fascia.In other embodiments one or more lighting devices may be position on theperimeter of the front panel and fascia to thereby illuminate the frontsurface of the mass confinement cell.

As previously suggested the environment resistant mass confinement cellis utilized in the construction of any type of wall, border orrevetment. In application, the confinement cells 10 are provided in adesired and assembled form. For various embodiments of the confinementcells 10 some assembly may be required, such as inserting the T-hooks orpegs into the T-slots or sockets or attaching the load cell 98 andfascia 68 to a front, back and/or side panels 12, 14, 16. Next, afoundation is prepared in the area that the wall, border or revetment isto be constructed. The foundation preferably is flat, compacted andlevel and can accommodate one or more mass confinement cells 10 andoptionally one or more cellular confinement systems. In variousembodiments, one or more courses of confinement cells 10 may bepartially submerged or totally submerged below the earth surface toprovide wall stability. Once a foundation is completed, a first row islaid by positioning the confinement cells 10 and optionally the cellularconfinement systems in their proper position side by side and fillingeach individual confinement cell 10 with a fill material while backfilling behind the row or filling the cellular confinement systemspositioned behind the cells 10 until the row is completed. A fillmaterial compacting device may be utilized while or after filling toensure stability of the fill material as the wall is constructed. Forexample, a packing device may be utilized to pack the fill materialafter filling each row of confinement cells 10 and/or cellularconfinement system. The chamber 18 is normally filled with materialssuch as sand, crushed rock, pea rock, gravel, dirt, cement, concrete orother beneficial materials to provide weight and structure stability tothe mass confinement cell 10 and the entire retaining wall. The fillingof the mass confinement cell 10 gives it the added weight that it needsto retain its structure and hold it in place. A funneling device (notshown) may be utilized, which fits securely into the openings orapertures of the mass confinement cell 10 to guide fill into the chamber18 of the cell 10. The first row and subsequent rows may be straight orcurved. Upon completion of the first row, additional rows areconstructed by placing the mass confinement cells 10 and optionally thecellular confinement system 132, in the proper position and performingthe same filling and back filling process until a continuous chamberretaining wall is completed. It is noted that with the continuouschamber system of the present invention, multiple rows can be secured inplace before filling and/or packing. However, it is recommended thatfilling and packing be done regularly (e.g. row by row) to ensure properpacking of the fill material.

Generally, a continuous chamber system retaining wall includes stackedrows wherein individual confinement cells 10 are placed adjacent to oneanother thereby eliminating or minimizing cracks or gaps in the wall.Rows of mass confinement cells 10 may be positioned directly over otherrows of mass confinement cells 10 wherein the cells 10 of each row arepositioned directly over other cells 10. However, many embodiments ofthe present invention provide a constructed wall wherein the massconfinement cells 10 are staggered in alternating rows as depicted inFIGS. 40 a-b. It is also noted, that the constructed wall may further besecured to the slope and the aggregate behind the wall can be furtherstabilized by positioning geogrid between rows of mass confinement cells10. Such action may be performed between each row or alternated every2-15 rows, and optionally every 3-10 rows.

Each mass confinement cell 10 placed in the retaining wall is configuredto retain and seal the contents of the fill material back towards theslope when the wall has been properly constructed. This may be furtheraccomplished by applying top covers 108 and/or bottom covers 110 that atleast partially seal the continuous chamber system. Alternatively,vegetation may be planted on the top row of the retaining wall to assistin sealing in the contents.

Furthermore, in various embodiments, the mass confinement cells 10 ofthe upper rows may be further positioned into place by an overlap of theback of confinement cells 10 of lower rows if a retaining flange or pegextensions 48 are included on the confinement cell 10. In thealternative or additionally, each individual confinement cell 10 may belocked into position with adjacent cells 10 if spools or reinforcingmembers and apertures, clipping devices 126 or hooks 128 are presentwith the confinement cell 10.

As previously mentioned, upon completion of the top row of the retainingwall, a cover, aesthetic top border or cell cap 138 may be placed on orover the top row to close and seal the continuous chamber system or toprovide an aesthetic finishing border to the top of the retaining wallor earth retention system. One embodiment of a cell cap 138, as depictedin FIG. 41, may be polygonal in shape and include textured and designedfaces on both the front panels 12, back panels 14 and top of the cellcap 138. The cell caps 138 may further include pegs (not shown), similarto those depicted in the previous confinement cell embodiments, that maybe utilized to secure the cell cap 138 to the mass confinement cells 10positioned below. Alternatively, the cell caps 138 may be secured to themass confinement cells 10 below by any means known in the art, such asclips, tacks, screws, rivets, adhesives or the like. The cell caps 138may be filled with a fill material, similar to the other embodiments ofthe present invention, or may be a thinner cap 138 that includes aplurality of reinforcing partitions or ribs 30.

FIG. 42 depicts another embodiment of a cell cap 138 that may beutilized with the mass confinement cell systems of the presentinvention. The cell cap 138 of the this embodiment is intended to whollyor partially cover the continuous flow chambers 18 of the confinementcells 10 positioned below when finishing the top course of a retainingwall or edges of a revetment. The cell cap 138 of this embodiment mayextend a distance from the front edge, or slightly overhanging the frontedge of the mass confinement cell 10 back over the top of the top courseof confinement cells 10. In various embodiments, the cell cap 138 mayextend back a distance of approximately between 5% to 110% of theconfinement cell 10. In various embodiments, this distance may translateto approximately 5 cm to 125 cm.

The cell cap 138 of this embodiment depicted in FIG. 42 generallyincludes a top cap 140, as depicted in FIG. 43 a, that is engageablewith a confinement cell cover 142, as depicted in FIG. 43 b. The cellcover 142 generally engages the confinement cell 10 positioned below andthereby is intended to lock the cell cap 138 into position on the wallor revetment. The cell cover 142 can engage the mass confinement cell 10positioned below utilizing one or more cover fasteners 144 that mayengage the confinement cell at any applicable surface (e.g. the frontpanel, side panels, partitions). The cover fasteners 144 may be any typeof fastening device, such as pegs, rivets, screws, adhesives, hooks,snaps, tabs and any other means that will secure the cell cap 138 to thecell confinement cells 10. The top cap 140 of this embodiment engagesthe cell cover 142 by any means to adequately secure the top cap 140 tothe cell cover 142. For example, snaps, pegs, tabs, adhesives and anyother means to fasten and secure the top cap may be utilized.Additionally, the top cap 140 may further include one or more ribs 30 toprovide additional structural support to the top cap 140. The cell cap138 may further include one or more end caps 146 that may be secured tothe ends of the cell cap 138 to close the outer edges. See FIGS. 43 c-dfor a front and back view of the endcap 146.

FIG. 44 depicts another embodiment of a cell cap 138 that may beutilized with the mass confinement cells 10 of the present invention.The cell cap 138 of this embodiment generally includes a top cap 140adjoined to a cell cover 142. The top cap 140 may be integrally adjoinedto the cell cover 142 or may be a separate component attachable to thecell cover 142. The top cap 138 may further include a plurality of ribs30 to provide additional stability and structure. Similar to theprevious embodiment, the cell cover 142 can engage the mass confinementcell 10 positioned below utilizing one or more cover fasteners (notshown) that may engage the confinement cell at any applicable surface(e.g. the front panel, side panels, partitions). The cover fasteners maybe any type of fastening device, such as pegs, rivets, screws,adhesives, hooks, snaps, tabs and any other means that will secure thecell cap 138 to the cell confinement cells 10. Additionally, the cellcap 138 of various embodiments may further include one or more extensionflaps 143 that bridge the gaps between adjacent cell caps 138. Theextension flaps 143 may be stationary and integrally attached or may bemoveable to retract or extend, thereby providing less or more length toeach flap 143. In various embodiments, the extension flaps may be placedon a track that allows for the extension or refraction of the flaps 143.

FIG. 45 depicts yet another embodiment of a cell cap 138 that may beutilized with the mass confinement cells 10 of the present invention.The cell cap 138 of this embodiment generally includes a top cap 140adjoined to a cell cover 142 and one or more anchoring devices. Theanchoring devices in this embodiment may include one or more arms 148that are operably adjoined to one or more peg extensions 48. The pegextensions 48 may further be locking peg extensions that are configuredto secure under an anchoring ridge or slot positioned in the back panelor load cell of the mass confinement cells 10 positioned below.Additionally, the arms 148 may be integrally adjoined to the top cap 140or adjoined with living hinges 150 and securing snaps, which would allowfor the cell cap 138 to be transported and/or stored in a flat or nestedconfiguration. Similar to the previous embodiments, the cell cover 142can engage the mass confinement cell 10 positioned below utilizing oneor more cover fasteners (not shown) that may engage the confinement cellat any applicable surface (e.g. the front panel, side panels,partitions). The cover fasteners may be any type of fastening device,such as pegs, rivets, screws, adhesives, hooks, snaps, tabs and anyother means that will secure the cell cap 138 to the cell confinementcells 10.

The top cap 140 of many embodiments will include the texture and colorof all the surfaces intended to be exposed on the front panel 12 orfascia 68 of the cell confinement systems 10 to provide a naturalearthen appearance and/or design. The top cap 140 may further include aplurality of ribs 28 to stabilize the top cap 142 and prevent crushingor damaging. The top cap 142 and top cover 142 in a number ofembodiments may be polygonal in shape, thereby allowing for a continuouscell cap 138 alignment over the length of a wall or revetment. Thepolygonal shape also allows for a continuous coverage when curving awall structure.

Embodiments of the present invention may also be used in conjunctionwith regular dry cement process blocks, bricks or stones, such as thoseproduced by Keystone®, Anchor® Wall Systems or Allan Block®. A retainingwall constructed in water or along a waterfront property may utilize themass confinement cells of the present invention at water level and belowand then the conventional retaining wall materials can be used on top ofthe mass confinement cells of the present invention. The utilization ofthe mass confinement cells of the present invention would allow ease inmatching colors with the conventional retaining wall building materialsbecause the materials utilized to manufacture the present invention canbe colored and designed to match virtually any type of retaining wallconstruction material.

Finally, the mass confinement cells may be manufactured in a multitudeof different sizes, shapes and configurations. For example, anembankment or steep shoreline could support a retaining wall configuredin a step like arrangement or design. Such a structure may be utilizedas a retaining wall and/or a stairway down to a beach or to the water.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, such an illustration and descriptionis to be considered as exemplary and not restrictive in character, itbeing understood that only the preferred embodiments have been shown anddescribed and that all changes and modifications that come within thespirit of the invention are desired to be protected.

1. A mass confinement cell comprising: a front panel including one ormore deterioration resistant composite or polymeric materials and havinga molded and/or fabricated front surface produced from a mold that has asurface formed from imaging an actual natural surface; the front surfaceis adjoined to or formed on the front panel to provide texture and colorthat mimics the actual natural surface; a back panel including one ormore deterioration resistant composite or polymeric materials; one ormore side panels including one or more deterioration resistant compositeor polymeric materials that are operably adjoined to one or both of thefront panel and back panel to form a chamber; and one or more lockingpeg extensions and one or more ridges or slots for accepting locking pegextensions from one or more adjacent cells.
 2. The mass confinement cellof claim 1, wherein the mass confinement cell has no bottom panel or apartial bottom panel and further includes an open top surface includingno top panel or a partial top panel extending from a front edge of thefront panel back a length no more than 75% of the width of the cell. 3.The mass confinement cell of claim 1 further including one or moresecuring mechanisms, wherein the one or more securing mechanisms includeintegral peg and socket systems.
 4. The mass confinement cell of claim 1wherein the composite or polymeric materials are selected from the groupconsisting of polyethylene, polypropylene, polyurethane,Acrylonitrile-butadiene-styrene (ABS), Polyethylene terephthalate (PET),polycarbonate, Poly(butylene terephthalate) (PBT),Poly(cyclohexanedimethylene terephthalate) (PCT), styrene-acrylonitrilecopolymers (SAN), polystyrene and combinations thereof.
 5. The massconfinement cell of claim 4, wherein the composite or polymeric materialincludes one or more filler materials, colors and/or additives.
 6. Themass confinement cell of claim 1 wherein the molded or fabricated frontsurface is molded or fabricated in the front panel.
 7. The massconfinement cell of claim 1 wherein the front panel includes a fasciahaving a molded or fabricated front surface.
 8. The mass confinementcell of claim 1, wherein the back panel and side panels are integrallyadjoined.
 9. The mass confinement cell of claim 1, wherein the frontpanel and side panels are integrally adjoined.
 10. The mass confinementcell of claim 4, wherein the imaging is performed by casting ordigitally scanning the actual natural surface.
 11. The mass confinementcell of claim 1, wherein the actual natural surface is formed from amold having the image of cut stone, brick or wood.
 12. The massconfinement cell of claim 1, further including a load cell positionedwithin the front panel and side panels.
 13. A method of building adeterioration resistant retaining wall comprising: a) placing aplurality of the mass confinement cells comprising a front panelincluding one or more deterioration resistant composite or polymericmaterials and having a molded and/or fabricated front surface producedfrom a mold that has a surface formed from imaging an actual naturalsurface; the front surface is adjoined to or formed on the front panelto provide texture and color that mimics the actual natural surface; aback panel including one or more deterioration resistant composite orpolymeric materials; one or more side panels including one or moredeterioration resistant composite or polymeric materials that areoperably adjoined to one or both of the front panel and back panel toform a chamber; and one or more locking peg extensions and one or moreridges or slots configured to receive locking peg extensions from one ormore adjacent cells; b) filling the chamber of each cell in the row withone or more fill materials; c) positioning a second row of massconfinement cells above the first row of mass confinement cells; d)filling the second row of mass confinement cells with a fill material;and e) continuing the previously described steps until the desirednumber of rows is achieved.
 14. The method of building a deteriorationresistant retaining wall of claim 13, wherein the mass confinement cellhas no bottom panel or a partial bottom panel and further includes anopen top surface including no top panel or a partial top panel extendingfrom a front edge of the front panel back a length no more than 75% ofthe width of the cell.
 15. The method of building a deteriorationresistant retaining wall of claim 13, wherein the composite or polymericmaterials are selected from the group consisting of polyethylene,polypropylene, polyurethane, Acrylonitrile-butadiene-styrene (ABS),Polyethylene terephthalate (PET), polycarbonate, Poly(butyleneterephthalate) (PBT), Poly(cyclohexanedimethylene terephthalate) (PCT),styrene-acrylonitrile copolymers (SAN), polystyrene and combinationsthereof.
 16. The method of building a deterioration resistant retainingwall of claim 13, wherein the composite or polymeric material includesone or more filler materials, colors and/or additives.
 17. The method ofbuilding a deterioration resistant retaining wall of claim 13, whereinthe molded or fabricated front surface is molded or fabricated in thefront panel or the front panel includes a fascia having a molded orfabricated front surface.
 18. The method of building a deteriorationresistant retaining wall of claim 13, wherein the imaging is performedby casting or digitally scanning the actual natural surface.
 19. Themethod of building a deterioration resistant retaining wall of claim 13,wherein the actual natural surface is formed from a mold having theimage of cut stone, brick or wood.
 20. The method of building adeterioration resistant retaining wall of claim 13, further including aload cell positioned within the front panel and side panels.